Power tool with battery pack enclosure

ABSTRACT

A power tool battery pack enclosure is configured to be retrofittedly coupled to battery pack receptacles of a plurality of power tools, each battery pack receptacle configured to removably receive a plurality of power tool battery packs. The enclosure includes a first clamshell member and a second clamshell member configured to be coupled around at least a portion of an exterior surface of each battery pack receptacle. Each of the first and second clamshell members have a top wall portion configured to be received over the exterior surface of the battery pack receptacle and a sidewall portion that extends downward from the top wall portion over at least a portion of the battery pack housing when the battery pack is received in the battery pack receptacle. The first and second enclosure members cover at least a portion of the battery back receptacle and at least a portion of the portion of a battery pack housing while allowing the battery pack to be removed from the battery pack receptacle while the enclosure remains coupled to the battery pack receptacle.

RELATED APPLICATION

This application claims priority, under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 63/028,622, filed May 22, 2020, titled“Power Tool with Battery Pack Enclosure,” which is incorporated byreference.

TECHNICAL FIELD

This application relates to a power tool with a battery pack enclosure.

BACKGROUND

Cordless power tools are powered by rechargeable battery packs that areremovably attachable to battery pack receptacles. A family of powertools may share a common battery pack receptacle and a common set ofbattery packs. In many such power tools, the battery packs remains atleast partially exposed from the power tools when the battery packs arecoupled to the power tools. When such power tools and battery packs areused in certain applications, the battery packs can be subjected tocontamination, e.g., by dust, spray fluids, moisture, cleaning fluids,and/or metal shavings.

SUMMARY

In an aspect, a power tool kit or system includes a power tool, abattery pack, and an enclosure. The power tool includes a tool housing,a motor received in the tool housing, an output member driven the motorand configured to perform an operation, and a battery pack receptaclecoupled to the tool housing. The battery pack receptacle includes anexterior surface and an interior portion that includes a firstmechanical and electrical interface. A battery pack includes a batteryhousing containing at least one battery cell and a second mechanical andelectrical interface coupled to the battery housing. The battery pack isconfigured to be removably coupled to the battery pack receptacle toprovide power to the motor with the second mechanical and electricalinterface received in the interior portion of the battery packreceptacle to be mechanically and electrically coupled with the firstmechanical and electrical interface and at least a portion of thebattery housing extending out of the interior portion of the batterypack receptacle. The enclosure has first and second enclosure membersconfigured to be retrofittedly coupled to the battery pack receptacle sothat the first and second enclosure members cover at least a portion ofthe battery back receptacle and at least a portion of the portion of thebattery housing that extends out of the interior portion of the batterypack receptacle while allowing the battery pack to be removed from thebattery pack receptacle while the enclosure remains coupled to thebattery pack receptacle.

Implementations of this aspect may include one or more of the followingfeatures. The tool housing may include a handle having a first endportion coupled to a remaining portion of the tool housing and a secondend portion coupled to the battery pack receptacle. The first endportion of the handle may have a first cross-sectional shape and thebattery pack receptacle may have a second cross-sectional shape that islarger than the first cross-sectional shape. The first mechanical andelectrical interface may include at least one first rail extendingtransverse to the handle and a first terminal block with a first set ofelectrical terminals. The second mechanical and electrical interface mayinclude at least one second rail configured to mechanically engage theat least one first rail and a second terminal block with a second set ofelectrical terminals configured to electrically couple to the first setof electrical terminals when the battery pack is received in the batterypack receptacle. The first mechanical and electrical interface mayinclude an elongated recess that extends into the handle and a first setof electrical terminals at a bottom of the recess in the handle. Thesecond mechanical and electrical interface may include a towerconfigured to be received in the recess and a second set of electricalterminals configured to electrically couple to the second set ofelectrical terminals when the battery pack is received in the batterypack receptacle.

The exterior surface of the battery pack receptacle may include a topsurface and a peripheral side surface. The first and second enclosuremembers may include a first clamshell member and a second clamshellmember configured to be retained around at least one of the top surfaceand the peripheral side surface. Each of the first and second clamshellmembers may have a top wall portion configured to be received over atleast one of the top surface and the peripheral side surface and asidewall portion that extends downward from the top wall portion overthe peripheral side surface and at least a portion of the batteryhousing when the battery pack is received in the battery packreceptacle. Each of the first and second clamshell members further mayinclude a bottom wall portion extending toward one another to cover abottom surface of the battery housing when the battery is received inthe battery receptacle. The battery enclosure further may include a doorcoupled to the first and second clamshell members, the door configuredto be openable to removably insert and remove the battery pack in thebattery pack receptacle. The first and second clamshell members and thedoor may completely enclose the battery pack when the battery pack isinserted into the battery pack receptacle. The enclosure may beconfigured to receive a plurality of different battery pack sizes withinthe enclosure.

The battery pack may include a latch and a button for actuating thelatch to removably lock the battery pack in the battery pack receptacle,the button being accessible for actuation when the door is opened. Thefirst and second clamshell members each may include an elastomericmember configured to form a seal between the clamshell members and thebattery pack receptacle. The first and second clamshell members may beconfigured to be snap fit to one another when received over the batterypack receptacle. The first and second clamshell members are configuredto be coupled to one another with one or more threaded fasteners. Theenclosure may be configured to be retrofittedly attached to a pluralityof other power tools each having a similarly configured battery packreceptacle.

In another aspect, a battery pack enclosure is configured to beretrofittedly coupled to a battery pack receptacle of a power tool,where the battery pack receptacle is configured to receive a removablebattery pack that has a mechanical and electrical interface received inan interior portion of the battery pack receptacle and a battery housingextending out of and exposed from the interior portion of the batterypack receptacle. The battery pack enclosure incudes first and secondenclosure members configured to be retrofittedly coupled to the batterypack receptacle so that the first and second enclosure members cover atleast a portion of the battery back receptacle and at least a portion ofthe portion of the battery housing that extends out of the interiorportion of the battery pack receptacle, allowing the battery pack to beremoved from the battery pack receptacle while the enclosure remainscoupled to the battery pack receptacle.

Implementations of this aspect may include one or more of the followingfeatures. The first and second enclosure members may include a firstclamshell member and a second clamshell member configured to be retainedaround at least one of a top surface and a peripheral side surface ofthe battery pack receptacle. Each of the first and second clamshellmembers may have a top wall portion configured to be received over atleast one of the top surface and the peripheral side surface and asidewall portion that extends downward from the top wall portion overthe peripheral side surface and at least a portion of the batteryhousing when the battery pack is received in the battery packreceptacle. Each of the first and second clamshell members further mayinclude a bottom wall portion extending toward one another to cover abottom surface of the battery housing when the battery is received inthe battery receptacle. The battery enclosure further may include a doorcoupled to the first and second clamshell members, the door configuredto be openable to removably insert and remove the battery pack in thebattery pack receptacle. The first and second clamshell members and thedoor may completely enclose the battery pack when the battery pack isinserted into the battery pack receptacle. The enclosure may beconfigured to receive a plurality of different battery pack sizes withinthe enclosure.

The battery pack received in the enclosure may include a latch and abutton for actuating the latch to removably lock the battery pack in thebattery pack receptacle, the button being accessible for actuation whenthe door is opened. The first and second clamshell members each mayinclude an elastomeric member configured to form a seal between theclamshell members and the battery pack receptacle. The first and secondclamshell members may be configured to be snap fit to one another whenreceived over the battery pack receptacle. The first and secondclamshell members may be configured to be coupled to one another withone or more threaded fasteners. The enclosure may be configured to beretrofittedly attached to a plurality of power tools each having asimilarly configured battery pack receptacle. The power tool may be afluid sprayer. The fluid sprayer may be configured to spray one or moreof paint, finish, architectural coating, disinfectant, sanitizer,decontaminate, cleaner, and deodorizer.

In another aspect, a modular battery pack enclosure for a power toolthat interfaces with a battery pack, the battery back attaching anddetaching from a handle portion of the power tool, includes a housing.The housing has a first opening configured to receive at least a part ofthe handle portion of the power tool, an internal cavity configured toaccommodate the battery pack, and a second opening configured to allowpassage of the battery pack into and out of the internal cavity. A dooris attached to the housing and moveable relative to the housing betweenan open position and a closed position relative to the housing. The doorcovers the second opening when in the closed position and the secondopening is exposed when the door is in the open position to allow thebattery pack to be inserted into and removed from the cavity of thehousing and to be coupled attached and detached from the handle portionof the power tool.

Implementations of this aspect may include one or more of the followingfeatures. The first opening of the housing may form a collar attachmentabout the part of the handle portion. The housing may include two sidepieces that attach together to attach the modular battery enclosure tothe handle portion of the power tool and separate to decouple themodular battery enclosure from the handle portion of the power tool.

In another aspect, a handheld fluid sprayer includes a sprayer housinghaving a handle, a reservoir supported by the sprayer housing, anelectric motor supported by the sprayer housing, and a pump supported bythe sprayer housing and operably connected to the electric motor to bepowered by the electric motor, the pump configured to pump fluid fromthe reservoir to a spray nozzle for spraying. A battery receptacle isdisposed at an end of the handle, the battery receptacle configured tomechanically and electrically connect to a battery to support thebattery on the sprayer housing. A battery enclosure is supported by thehandle, the battery enclosure configured to cover at least a portion ofthe battery receptacle and at least a portion of a battery housing of abattery mounted to the battery receptacle. The battery enclosure isconfigured such that the battery can be mounted to and dismounted fromthe battery receptacle with the battery enclosure supported by thehandle.

Implementations of this aspect may include one or more of the followingfeatures. The battery enclosure may be formed from a clamshell. Thebattery enclosure may include a first enclosure member having a firsttop wall and a first peripheral side wall, and a second enclosure memberhaving a second top wall and a second peripheral side wall. The firstenclosure member may further include a first bottom wall spaced from thefirst top wall by the first peripheral side wall. The second enclosuremember may further include a second bottom wall spaced from the secondtop wall by the second peripheral side wall. The first bottom wall andthe second bottom wall may cover a bottom side of the battery housing ofthe battery. A drainage opening may be formed through at least one ofthe first bottom wall and the second bottom wall. A first elastomericmember may be supported by the first top wall, the first elastomericmember configured to interface with the first enclosure member and oneof the handle and the battery pack receptacle to form a fluid-tightseal.

The battery enclosure may further include a door supported by a body ofthe battery enclosure, the door configured to move between a closedstate and an open state, wherein the door covers an opening defined atleast partially by the body of the battery enclosure when the door is inthe closed state, and wherein the door uncovers the opening when thedoor is in the open state such that the battery can be mounted to anddismounted from the battery receptacle with the door in the open state.The door may be pivotably mounted to the body of the battery enclosure.The battery may be fully enclosed within the battery enclosure with thedoor in the closed state. The battery enclosure may be mounted to thebattery receptacle.

In another aspect, a battery enclosure for covering at least a portionof a battery is mounted to a battery receptacle disposed at an end of ahandle of a sprayer housing of a handheld fluid sprayer to power anelectric motor of the handheld fluid sprayer. The battery enclosureincludes a first enclosure member having a first top wall configured toextend partially around the battery and a first peripheral side wall,the first peripheral side wall extending downward from the first topwall, and a second enclosure member having a second top wall and asecond peripheral side wall, the second peripheral sidewall extendingdownward from the second top wall. The second enclosure member may beconfigured to mate with the first enclosure member in a clamshell overone of a top surface of the battery pack receptacle and a side surfaceof the battery pack receptacle.

Implementations of this aspect may include one or more of the followingfeatures. The battery enclosure may be configured to cover at least aportion of the battery receptacle and at least a portion of a batteryhousing of the battery mounted to the battery receptacle. The batteryenclosure may be configured such that the battery can be mounted to anddismounted from the battery receptacle with the battery enclosuresupported by the handle. The battery enclosure may further include afirst elastomeric member supported by the first top wall, and a secondelastomeric member supported by the second top wall. The firstelastomeric member and the second elastomeric member may be configuredto interface with one of the handle and the battery pack receptacle toform a fluid-tight seal.

The first enclosure member may include a first bottom wall spaced fromthe first top wall by the first peripheral side wall, and the secondenclosure member may include a second bottom wall spaced from the secondtop wall by the second peripheral side wall. The first bottom wall maybe configured to mate with the second bottom wall. A drainage openingmay be formed through at least one of the first bottom wall and thesecond bottom wall. The battery enclosure may include a door supportedby a body of the battery enclosure, the door configured to move betweena closed state and an open state. The door may be pivotably mounted tothe body of the battery enclosure. The battery enclosure may be fullyenclosed with the door in the closed state. The first enclosure memberand the second enclosure member may mate to define an opening such thatthe battery can slide onto the battery receptacle through the openingduring mounting and the battery can slide off of the battery receptaclethrough the opening during dismounting. The first enclosure member maybe fixed to the second enclosure member by a plurality of fasteners.

In another aspect, a handheld fluid sprayer includes a sprayer housinghaving a handle, a reservoir supported by the sprayer housing, anelectric motor supported by the sprayer housing, and a pump supported bythe sprayer housing and operably connected to the electric motor to bepowered by the electric motor, the pump configured to pump fluid fromthe reservoir to a spray nozzle for spraying. A battery receptacle isdisposed at an end of the handle, the battery receptacle configured tomechanically and electrically connect to a battery to support thebattery on the sprayer housing. A battery enclosure is supported by thehandle, the battery enclosure formed in a clamshell by a first enclosuremember and a second enclosure member. The battery enclosure isconfigured to cover at least a portion of the battery receptacle and atleast a portion of a battery housing of a battery mounted to the batteryreceptacle. The battery enclosure is configured such that the batterycan be mounted to and dismounted from the battery receptacle with thebattery enclosure supported by the handle.

Implementations of this aspect may include one or more of the followingfeatures. The first enclosure member may include a first top wall, afirst peripheral side wall, and a first bottom wall spaced from thefirst top wall by the first peripheral side wall. The second enclosuremember may include a second top wall, a second peripheral side wall, anda second bottom wall spaced from the second top wall by the secondperipheral side wall. The first bottom wall and the second bottom wallmay cover a bottom side of the battery housing of the battery. Thebattery enclosure may include a door supported by a body of the batteryenclosure, the door configured to move between a closed state and anopen state. The door may cover an opening defined at least partially bythe body of the battery enclosure when the door is in the closed state,and the door may uncover the opening when the door is in the open statesuch that the battery can be mounted to and dismounted from the batteryreceptacle with the door in the open state. The battery may be fullyenclosed within the battery enclosure with the door in the closed state.The battery may be configured to mount to the battery receptacle by asliding interface such that the battery slides away from the reservoirduring dismounting. The battery enclosure may include a top side, abottom side, a plurality of peripheral sides, and a door movable betweenan open state and a closed state. The door may be configured to uncoveran opening through which the battery can be mounted and dismounted withthe door in the open state and wherein the door is configured to coverthe opening with the door in the closed state.

Advantages may include one or more of the following. The battery packenclosure may help protect the battery pack from contamination, e.g., bydust, moisture, cleaning fluids, and/or metal shavings, whileaccommodating a variety of configurations of battery packs and enablingfast and easy insertion and removal of the battery packs from the powertools. The battery pack enclosure may also be used to retrofit anenclosure on a variety of similarly configured power tools in a powertool family. These and other advantages and features will be apparentfrom the description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a power tool.

FIG. 2 is a side view of the power tool of FIG. 1 with a portion of thetool housing removed.

FIGS. 3 and 4 are perspective views of an embodiment of a battery packfor use with the power tool of FIG. 1.

FIGS. 4A-4D are side views of additional embodiments of battery packsfor use with the power tool of FIG. 1.

FIGS. 5A-5B are perspective views of another embodiment of a power toolusable with the battery packs of FIGS. 3-4D.

FIG. 6A-6B are perspective views of the power tool of FIGS. 5A-5B withan embodiment of a battery pack enclosure retrofittedly coupled to thepower tool.

FIG. 6C is a perspective view of the power tool and battery packenclosure of FIGS. 6A-6B, with a portion of the tool housing removed.

FIG. 7 is an exploded view of the battery enclosure of FIGS. 6A-6B.

FIG. 8 is a rear perspective view of the battery enclosure of FIGS.6A-6B coupled to the power tool of FIGS. 5A-5B.

FIG. 9 is a cross-sectional view of the battery enclosure of FIGS. 6A-6Bwith several battery packs shown schematically coupled to the powertool.

FIG. 10A is a schematic view of the battery enclosure of FIGS. 6A-6Bcoupleable to additional embodiments of power tools.

FIG. 10B is a schematic view of the battery enclosure of FIGS. 6A-6Bcoupleable to additional embodiments of power tools.

FIG. 11 is a perspective view of another embodiment of an enclosurecoupled to the power tool of FIGS. 5A-5B.

FIG. 12 is a perspective view of another embodiment of a power tool andbattery pack usable with the disclosed battery pack enclosures.

FIGS. 13A-13B are perspective views of another embodiment of a batterypack enclosure retrofittedly coupled to one of the aforementioned powertools.

FIGS. 13A-13B are perspective views of another embodiment of a batterypack enclosure retrofittedly coupled to one of the aforementioned powertools.

FIG. 14 is a perspective view of another embodiment of a battery packenclosure retrofittedly coupled to one of the aforementioned powertools.

FIG. 15 is a perspective view of another embodiment of a battery packenclosure retrofittedly coupled to one of the aforementioned powertools.

FIG. 16 is a perspective view of another embodiment of a battery packenclosure retrofittedly coupled to one of the aforementioned powertools.

FIG. 17 is a perspective view of another embodiment of a battery packenclosure retrofittedly coupled to one of the aforementioned powertools.

FIG. 18 is a perspective view of another embodiment of a battery packenclosure retrofittedly coupled to one of the aforementioned powertools.

DETAILED DESCRIPTION

Referring to FIGS. 1-4, a system or kit 10 of power tools and batterypacks include a first power tool 12 and a first battery pack 14. Thefirst power tool 12 (e.g., an impact driver) includes a tool housing 16having a motor housing 18, a transmission housing 20 extending forwardof the motor housing 18, and a handle 22 having a first end portion 21coupled to the motor housing 18. An electric motor 22 is received in thetool housing 16 (e.g., in the motor housing 18) and is configured todrive an output member 24 to perform an operation (e.g., drilling ahole, driving a fastener, spraying a solution) on a workpiece. Atransmission (not shown) (e.g., a planetary gear transmission and/or arotary impact mechanism) is received in the transmission housing 20 andconfigured to transmit rotary output from the motor 22 to the outputmember 24 to perform the operation. Received in the handle is aswitching member 26 actuated by an external trigger 28 and a controlmodule or circuit 29 (e.g., including a microcontroller) that controlspower delivery to the motor 22.

Coupled to a second end portion 30 of the handle 22 is a batteryreceptacle 32. The end portion 30 of the handle has a first shape 23with a first cross-sectional area and the battery pack receptacle has asecond shape 33 with a second cross-sectional area that is larger thanthe first cross-sectional area. The battery pack receptacle 32 includean exterior surface 34 and an interior portion 36 that includes a firstmechanical and electrical interface 38. The interior portion 36 includesa first pair of rails 40 extending transverse to the handle 22 a firstterminal block 42 that includes a first plurality of electricalterminals (not shown). The battery receptacle 32 is configured toremovably receive the first battery pack 14. The exterior surface 34includes a top surface 46 and a downwardly projecting peripheral surface48.

The first battery pack 14 includes a battery housing 50 containing atleast one battery cell (not shown) and a second mechanical andelectrical interface 52 coupled to the battery housing 50. The batterypack 14 is configured to be removably coupled to the battery packreceptacle 32 on the power tool 12 to provide power to the motor 22.When coupled to the power tool 12, the second mechanical and electricalinterface 52 is received in the interior portion 36 of the battery packreceptacle 32 and at least a portion of the battery housing 50 extendingout of the interior portion of the battery pack receptacle 32. Thesecond mechanical and electrical interface 52 includes a pair of secondrails 54 configured to mechanically engage the first rails 40 in thebattery receptacle 32 and a second terminal block 56 with a second setof electrical terminals 58 configured to electrically couple to thefirst set of electrical terminals 42 when the battery pack 50 isreceived in the battery pack receptacle 32. The first battery pack 14also includes a latch 60 configured to releasably lock the battery pack14 in the battery receptacle 14 when it is received in the battery packreceptacle 32 and a button 62 configured to be actuated by a user'sfinger to disengage the latch 60 to remove the battery pack 50 from thebattery pack receptacle 50.

Referring also to FIGS. 4A-4D, the system or kit 10 may include aplurality of additional battery packs 114, 214, 314, 414. Each of thebattery packs 114, 214, 314, 414 has a second mechanical and electricalinterface 152, 252, 352, 452 that is substantially the same as thebattery pack interface 52 on the first battery pack 14 and has a similaroperating voltage (e.g., 18V or 20V) to enable the battery packs 114,214, 314, 414 to be used interchangeably with the first power tool 12.The battery packs 114, 214, 314, 414 differ from the first battery pack14 in that each of them has a battery pack housing 150, 250, 350, 450that is at least somewhat different in size, dimensions, and/orconfiguration than the housing 50 of the first battery pack 14. Thehousings 150, 250, 350, 450 may be different to accommodate differentquantities and arrangements of battery cells so that the battery packs114, 214, 314, 414 may have different capacities (e.g., 1.5 Ah, 5 Ah, 6Ah, and 9 Ah, respectively).

The system or kit 10 also may include one or more additional power toolsand other related products (e.g., drills, impact wrenches, circularsaws, reciprocating saws, miter saws, grinders, nailers, lights, radios,speakers, fluid sprayers, and rotary hammers) that may be powered by oneor more of the battery packs 14, 114, 214, 314, 414. For example, asshown in FIGS. 5A-5B and 6C, the system or kit 10 may include a secondpower tool 112 (e.g., a sprayer) having a tool housing 116 that includesa motor housing 118 and a handle 120. The motor housing 118 contains apump 121 and an electric motor 122 configured to operate the pump 121.The pump 121 can be any type of pump, such as a piston or diaphragmpump. The second power tool 112 includes a spray tip 113 with a spraynozzle 115 for atomizing a spray fluid (e.g., paints, finishes,architectural coatings, disinfectants, sanitizers, decontaminates,cleaners, deodorizers, and/or similar fluids) in a spray fan forapplication to a surface. The second power tool 112 includes, in thisembodiment, a reservoir 117 for holding the spray fluid, and from whichthe pump draws. The handle 120 has a first end portion 121 coupled tothe motor housing 118 with a trigger 119 for controlling power deliveryto the motor. Coupled to a second end portion 130 of the handle 120 is abattery receptacle 132 having a configuration substantially similar tothe battery receptacle 32 of the first power tool 12. The battery packreceptacle 132 includes an exterior surface 134 and an interior portion136 that includes a first mechanical and electrical interface 138similar to the first mechanical and electrical interface 38. The batteryreceptacle 132 is configured to removably receive one or more of thebattery packs 14, 114, 214, 314, 414. The exterior surface 134 includesa top surface 146 and a downwardly projecting peripheral surface 148.The battery receptacle 132 includes a control board 135 with acontroller or control circuit configured to control power delivery tothe motor 122 in response to input from the trigger 119.

Referring also to FIGS. 6A-7, in order to protect the battery packs fromcontamination, e.g., due to dust, moisture, fluids (e.g., cleaning,disinfection, etc.), and/or metal shavings, an enclosure 64 may beprovided that can be retrofitted onto the battery pack receptacles 32,132. In an embodiment, the enclosure 64 includes first and secondenclosure members 66, 68 configured to be retrofittedly coupled to thebattery pack receptacles 32, 132 so that the first and second enclosuremembers 66, 68 cover at least a portion of the battery back receptacle32, 132 and at least a portion of the portion of the battery housing 50,150, 250, 350, 450 that extends out of the interior portion of thebattery pack receptacle 32, 132 while allowing the battery pack to beremoved from the battery pack receptacle 64 with the enclosure remainingcoupled to the battery pack receptacle 32, 132. The first and secondenclosure members 66, 68 comprise a first clamshell member 70 and asecond clamshell member 72 configured to be retained around at least oneof the top surface 46, 146 and the peripheral side surface 48, 148 ofthe battery pack receptacle 32, 132. Each of the first and secondclamshell members 70, 72 has a top wall portion 74, 76 configured to bereceived over at least one of the top surface 46, 146 and the peripheralside surface 48, 148 of the battery pack receptacle 32, 132. The firstand second clamshell members 70, 72 also each have a sidewall portion78, 80 that extends downward from the top wall portion 74, 76 over theperipheral side surface 48, 148 of the battery pack receptacle 32, 132and over at least a portion of the battery housing 50, 150, 250, 350,450 when the battery pack 14, 114, 214, 314, 414 is received in thebattery pack receptacle 32, 132.

Each of the first and second clamshell member 70, 72 may further includea bottom wall portion 82, 84 extending toward one another to cover abottom surface of the battery housing 50, 150, 250, 350, 450 when thebattery pack 14, 114, 214, 314, 414 is received in the battery packreceptacle 32, 132. The bottom wall portions 82, 84 may optionallyinclude small openings 85 configured to allow fluids to drain from theenclosure 64 and/or to enable cooling airflow into the enclosure 64. Thebattery enclosure 64 may further include a door 86 pivotably coupled tothe first and second clamshell members 70, 72 by a pair of bearing pins88 fastened to bosses 90 in the first and second clamshells 70, 72 bythreaded fasteners 90. The door 86 is configured to be openable toaccess the button 60 to disengage the latch 62 and to removably insertand remove the battery pack 14, 114, 214, 314, 414 in the battery packreceptacle 32, 132. In the embodiment illustrated in FIGS. 6A-7, thefirst and second clamshell members 70, 72 and the door completelyenclose the battery pack 14, 114, 214, 314, 414 when the battery pack isreceived in the battery pack receptacle 32, 132.

The first and second clamshell members 70, 72 may each include one orelastomeric members 92 configured to form a seal between the clamshellmembers 70, 72 and the battery pack receptacle 32, 132. The first andsecond clamshell members 70, 72 are attached to one another by aplurality of threaded fasteners 94 received in screw bosses 96 in theclamshells 70, 72. In other embodiments, the first and second clamshellmembers may be configured to snap fit to one another when received overthe battery pack receptacle. In yet other embodiments, the enclosure mayslides into and latch to the battery pack receptacle using rails and theterminal block in the battery pack receptacle and rails corresponding, alatch and a terminal block in the enclosure.

Referring also to FIG. 9, the enclosure 64 may be sized and configuredlarge enough to receive a plurality of different battery pack sizes(e.g., battery packs 114 and 214 as schematically illustrated in FIG. 9,but also battery packs 14, 314, 414) within the enclosure 64.

Referring also to FIGS. 10A-10B, the enclosure 64 may be configured tobe retrofittedely attached to a plurality of other power tools 212 a,312 a, 412 a, 212 b, 312 b, each having a similarly configured batterypack receptacle 232 a, 332 a, 432 a, 232 b, 332 b. With respect to thepower tools 212 b, 312 b, the enclosure 64 may be configured to beretrofittedely attached to their battery pack receptacles 232 b, 332 b,while leaving their light units 234 b, 334 b, and their control switches236 b, 336 b, exposed and user-accessible. In each of these embodiments,the enclosure or its components may be coupled to the battery packreceptacles in other manners, e.g., by interference fit with protrusionsor recesses on the battery pack receptacles or by threaded fastenersreceived in threaded openings 238 b, 338 b, which are alternatively usedto couple a belt clip 240 a, 240 b to the battery pack receptacle afterremoving the belt clip.

Referring to FIG. 11, another embodiment of an enclosure 164 isconfigured to be retrofittedely coupled to the power tool 112 (or topower tools 12, 212 a, 312 a, 412 a, 212 b, 312 b). The enclosure 164comprises first and second enclosure members 166, 168 including a firstclamshell member 170 and a second clamshell member 172. The clamshellmembers 170, 172 are configured to be retained around at least one ofthe top surface 146 and the peripheral side surface 148 of the batterypack receptacle 132. Each of the first and second clamshell members 170,172 has a top wall portion 174, 176 configured to be received over atleast one of the top surface 146 and the peripheral side surface 148 ofthe battery pack receptacle 132. The first and second clamshell members170, 172 also each have a sidewall portion 178, 180 that extendsdownward from the top wall portion 174, 176 over the peripheral sidesurface 148 of the battery pack receptacle 32, 132 and over only aportion of the battery housing 50 when the battery pack 14 is receivedin the battery pack receptacle 132. The clamshells 170, 172 are snap fittogether, but can be attached by fasteners such as screws. The enclosure164 is open at the bottom so as to accommodate a variety of sizes ofbattery packs, to allow airflow to reach vents 51 in the bottom of thebattery pack, and to allow a user to see an indicator of remainingcharge 53 on the battery pack housing 50.

Referring to FIG. 12, the enclosures 64, 164 may be usable with analternative embodiment of a power tool 512 and battery pack 514. Thepower tool 512 (e.g., an impact driver) includes a tool housing 516having a motor housing 518, a transmission housing 520 extending forwardof the motor housing 518, and a handle 522 having a first end portion521 coupled to the motor housing 518. Coupled to a second end portion530 of the handle 522 is a battery receptacle 532. The batteryreceptacle 532 include an exterior surface 534 and an interior portion536 that includes a first mechanical and electrical interface 538. Thefirst mechanical and electrical interface 538 includes an elongatedrecess that extends into the handle 522 and a first set of electricalterminals at a top of the recess in the handle. The battery pack 514includes a battery housing 550 containing at least one battery cell (notshown) and a second mechanical and electrical interface 552 coupled tothe battery housing 550. The battery pack 514 is configured to beremovably coupled to the battery pack receptacle 532 on the power tool512 to provide power to the motor. The second mechanical and electricalinterface 552 includes a tower 554 configured to be received in therecess in the handle 522 and a second set of electrical terminals 556configured to electrically couple to the second set of electricalterminals when the battery pack is received in the battery packreceptacle. When coupled to the power tool 512, at least a portion ofthe battery housing 550 extends out of the of the battery packreceptacle 532. The battery pack 514 also has a latch 560 for lockingthe battery pack 514 in the battery pack receptacle 532 and a button 562for disengaging the latch 560 to remove the battery pack 514 from thereceptacle 532. The enclosure 164 of FIG. 11 can be coupled to thebattery back receptacle 532 with little or no modification. Theenclosure 64 of FIG. 7 can be coupled to the battery pack receptacle 532if modified so that that door to the enclosure is on the bottom of thereceptacle 532, allowing the battery pack 514 to be accessed to removethe battery pack 514 from the power tool 512.

Referring to FIGS. 13A-13B, in another embodiment, an enclosure 264 isconfigured to be retrofittedely coupled to the battery pack receptacle132 of the power tool 112 (or to power tools 12, 212 a, 312 a, 412 a,212 b, 312 b). The enclosure 264 comprises first and second enclosuremembers 266, 268 including a first clamshell member 270 and a secondclamshell member 272. The clamshell members 270, 272 are configured tobe retained around at least one of the top surface and the peripheralside surface of the battery pack receptacle 132. Each of the first andsecond clamshell members 270, 272 has a top wall portion 274, 276configured to be received over at least one of the top surface 146 and abox-shaped sidewall portions 278, 280 that extend downward from the topwall portions 174, 176 over the peripheral side surface 148 of thebattery pack receptacle 132 and over at least a portion of the batteryhousing 50 when the battery pack 14 is received in the battery packreceptacle 132. The clamshells 270, 272 may be snap fit together, butcan be attached by fasteners such as screws to each other or to thebattery pack receptacle. The enclosure 264 further includes a box shapedbase 282 having a bottom wall portion 284 generally parallel to the topwall portions 274, 276 and an accordion-style sidewall portion 286extending upward from the bottom wall portion 284. The accordion-stylesidewall portion 286 is joined to the sidewall portions 278, 280 by oneor more latches 288 that can be opened to allow access to an interior ofthe enclosure 264 to install or remove the battery pack 14 from thebattery pack receptacle. The accordion-style sidewall portion 286 isadjustable in order to accommodate different sizes and configurations ofbattery packs.

Referring to FIGS. 14-15, in another embodiment, an enclosure 364 isconfigured to be retrofittedely coupled to the battery pack receptacle132 of the power tool 112 (or to the battery pack receptacles of one ofthe other power tools 12, 212 a, 312 a, 412 a, 212 b, 312 b). Theenclosure 364 is substantially similar to the enclosure 164 shown inFIGS. 6A-7, with the following differences. The enclosure 364 includesfirst and second clamshell members 370, 372 and a door 386 pivotablycoupled to the first and second clamshell members 370, 372,substantially similar to the first and second clamshell members 170, 172and door 186. The enclosure 364 additionally includes at least onepressure relief device 390 coupled to at least one of the clamshellmembers 370, 372 and the door 386. The pressure relief device 390 mayinclude a valve 392 (as shown in FIG. 14), a pressure relief vent ormember 394 (such as a GORE® PolyVent protective vent sold by W.L. Gore &Associates, Inc.) that enables ingress and egress of air whilepreventing ingress of moisture (as shown in FIG. 15), a blow-out valve,or a weak point in one of the walls. The pressure relief device 380 isconfigured to relieve outgas and relieve pressure inside the enclosure,e.g., due to battery pack heating during use. This may be desirable whenthe enclosure forms a water-tight or air-tight seal around the batterypack.

Referring to FIG. 16, in another embodiment, an enclosure 464 isconfigured to be retrofittedely coupled to the battery pack receptacle132 of the power tool 112 (or to the battery pack receptacles of one ofthe other power tools 12, 212 a, 312 a, 412 a, 212 b, 312 b). Theenclosure 464 is substantially similar to the enclosure 164 shown inFIGS. 6A-7, with the following differences. The enclosure 464 includesfirst and second clamshell members 470, 472 and a door 486 pivotablycoupled to the first and second clamshell members 470, 472,substantially similar to the first and second clamshell members 170, 172and door 186. The enclosure 464 additionally includes a security tag ordevice 490 (or a mounting location for such a security tag or device)coupled to at least one of the clamshell members 470, 472 and the door486. The security tag or device 390 (e.g., a RFID tag, anelectro-magnetic tag, an acousto-magnetic tag, or a microwave tag). Thesecurity tag or device 390 may be used to track and/or prevent theft ofthe power tool, the enclosure, and or the battery pack.

Referring to FIG. 17, in another embodiment, an enclosure 564 isconfigured to be retrofittedely coupled to the battery pack receptacle132 of the power tool 112 (or to the battery pack receptacles of one ofthe other power tools 12, 212 a, 312 a, 412 a, 212 b, 312 b). Theenclosure 564 is substantially similar to the enclosure 164 shown inFIGS. 6A-7, with the following differences. The enclosure 564 includesfirst and second clamshell members 570, 572 and a door 586 pivotablycoupled to the first and second clamshell members 570, 572,substantially similar to the first and second clamshell members 170, 172and door 186. The enclosure 564 additionally includes a lock 590 coupledto the door 586 and to one or more of one of the clamshell members 570,572. The lock 590 may be a mechanical lock (e.g., a padlock, acombination lock, or a key lock) or may be an electromechanical lock(e.g., an electromagnetic latch). The lock 590 may be used to preventopening of the door 186 to prevent theft of the battery pack.

Referring to FIG. 18, in another embodiment, an enclosure 664 isconfigured to be retrofittedely coupled to the battery pack receptacle132 of the power tool 112 (or to the battery pack receptacles of one ofthe other power tools 12, 212 a, 312 a, 412 a, 212 b, 312 b). Theenclosure 664 is substantially similar to the enclosure 164 shown inFIGS. 6A-7, with the following differences. The enclosure 664 includesfirst and second clamshell members 670, 672 and a door 686 pivotablycoupled to the first and second clamshell members 670, 672,substantially similar to the first and second clamshell members 170, 172and door 186. The enclosure 664 additionally includes a tetheringattachment 690 coupled to one of the clamshell members 670, 672 and thedoor 686. The tethering attachment 690 is configured to receive atethering strap 692 (e.g., a lanyard) that can be used to tether theenclosure 664 or the power tool 132 to a person or a stationary objectto prevent the power tool from falling if it is dropped while working.Exemplary tethering attachments and tethering straps are described,e.g., in U.S. Pat. App. Pub. No. 2020/0194747, which is incorporated byreference.

Example embodiments have been provided so that this disclosure will bethorough, and to fully convey the scope to those who are skilled in theart. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Terms of degree such as “generally,” “substantially,” “approximately,”and “about” may be used herein when describing the relative positions,sizes, dimensions, or values of various elements, components, regions,layers and/or sections. These terms mean that such relative positions,sizes, dimensions, or values are within the defined range or comparison(e.g., equal or close to equal) with sufficient precision as would beunderstood by one of ordinary skill in the art in the context of thevarious elements, components, regions, layers and/or sections beingdescribed.

Numerous modifications may be made to the exemplary implementationsdescribed above. These and other implementations are within the scope ofthis application.

What is claimed is:
 1. A power tool system comprising: a power toolincluding a tool housing, a motor received in the tool housing, anoutput member driven the motor and configured to perform an operation ona workpiece, and a battery pack receptacle coupled to the tool housing,the battery pack receptacle including a first mechanical and electricalinterface; a battery pack removably coupleable to the power tool, thebattery pack including a battery pack housing and a second mechanicaland electrical interface configured to be mechanically and electricallycoupled with the first mechanical and electrical interface of thebattery pack receptacle; and an enclosure having first and secondenclosure members configured to be retrofittedly coupled to the batterypack receptacle so that the first and second enclosure members cover atleast a portion of the battery back receptacle and at least a portion ofthe portion of the battery pack housing while allowing the battery packto be removed from the battery pack receptacle while the enclosureremains coupled to the battery pack receptacle.
 2. The power tool systemof claim 1, wherein the first and second enclosure members include afirst clamshell member and a second clamshell member configured to becoupled around at least a portion of an exterior surface of the batterypack receptacle.
 3. The power tool system of claim 2, wherein each ofthe first and second clamshell members includes a top wall portionconfigured to be received over the exterior surface of the battery packreceptacle and a sidewall portion that extends downward from the topwall portion over at least a portion of the battery pack housing whenthe battery pack is received in the battery pack receptacle.
 4. Thepower tool system of claim 3, wherein each of the first and secondclamshell members further includes a bottom wall portion extending fromthe sidewall portions toward one another to cover a bottom surface ofthe battery pack housing when the battery pack is received in thebattery pack receptacle.
 5. The power tool system of claim 3, whereinthe enclosure further comprises a door coupled to the first and secondclamshell members, the door configured to be openable to removablyinsert the battery pack into the battery pack receptacle.
 6. The powertool system of claim 5, wherein the first and second clamshell membersand the door substantially completely enclose the battery pack when thebattery pack is inserted into the battery pack receptacle.
 7. The powertool system of claim 1, wherein the enclosure is configured to receive aplurality of different battery pack sizes within the enclosure.
 8. Thepower tool system of claim 1, wherein the first and second enclosuremembers each include an elastomeric member configured to form a sealbetween the enclosure members and the battery pack receptacle.
 9. Thepower tool system of claim 1, wherein the first and second enclosuremembers are configured to be coupled to battery pack receptacle by atleast one of a snap-fit connection and a threaded fastener.
 10. Thepower tool system of claim 1, wherein a size of the battery packenclosure is user adjustable.
 11. The power tool system of claim 1,wherein the battery pack enclosure includes at least one accordion-stylewall portion to facilitate user adjustment of the size of the enclosure.12. The power tool system of claim 1, wherein the enclosure isconfigured to be retrofittedly attachable to a plurality of other powertools each having a similarly configured battery pack receptacle. 13.The power tool system of claim 1, wherein the power tool includes atleast one of a light unit and a control switch coupled to the batterypack receptacle, wherein the enclosure is configured to leave the atleast one of the light unit and the control switch exposed when theenclosure is coupled to the battery pack receptacle.
 14. The power toolsystem of claim 1, wherein the power tool comprises one of a drill, adrill/driver, an impact driver an impact wrench, a reciprocating saw, acircular saw, a grinder, a hammer drill, a nailer, an oscillatingmulti-tool, and a sprayer.
 15. A power tool battery pack enclosureconfigured to be retrofittedly coupled to battery pack receptacles of aplurality of power tools, each battery pack receptacle configured toremovably receive a plurality of power tool battery packs, the enclosurecomprising: a first clamshell member and a second clamshell memberconfigured to be coupled around at least a portion of an exteriorsurface of each battery pack receptacle, each of the first and secondclamshell members having a top wall portion configured to be receivedover the exterior surface of the battery pack receptacle and a sidewallportion that extends downward from the top wall portion over at least aportion of the battery pack housing when the battery pack is received inthe battery pack receptacle, such that the first and second enclosuremembers cover at least a portion of the battery back receptacle and atleast a portion of the portion of a battery pack housing while allowingthe battery pack to be removed from the battery pack receptacle whilethe enclosure remains coupled to the battery pack receptacle.
 16. Theenclosure of claim 15, wherein each of the first and second clamshellmembers further include a bottom wall portion extending from thesidewall portions toward one another to cover a bottom surface of thebattery pack housing when the battery pack is received in the batterypack receptacle.
 17. The enclosure of claim 16, further comprising adoor coupled to the first and second clamshell members, the doorconfigured to be openable to removably insert the battery pack into thebattery pack receptacle.
 18. The enclosure of claim 17, wherein thefirst and second clamshell members and the door substantially completelyenclose the battery pack when the battery pack is inserted into thebattery pack receptacle.
 19. The enclosure of claim 15, wherein theenclosure is configured to receive a plurality of different battery packsizes within the enclosure.
 20. The enclosure of claim 15, wherein thefirst and second enclosure members each include an elastomeric memberconfigured to form a seal between the enclosure members and the batterypack receptacle.